Light-emitting apparatus including sacrificial pattern

ABSTRACT

A light-emitting apparatus includes a substrate, pads disposed on the substrate, a sacrificial pattern layer and a light-emitting diode element disposed on the sacrificial pattern layer. The light-emitting diode element includes a first type semiconductor layer, a second type semiconductor layer, an active layer, and electrodes. A connection patterns disposed on at least one of the electrodes and the pads. Materials of the connection patterns include hot fluidity conductive materials. The connection patterns cover an outermost sidewall of the sacrificial pattern layer and are electrically connected to the at least one of the electrodes and the pads. The sacrificial pattern layer is located between the connection patterns, and the sacrificial pattern layer is overlapped with the pads in a normal direction of the substrate.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application of U.S. application Ser.No. 16/518,962, filed on Jul. 22, 2019, now pending, which claims thepriority benefit of Taiwan application serial no. 108100342, filed onJan. 4, 2019. The entirety of each of the above-mentioned patentapplications is hereby incorporated by reference herein and made a partof this specification.

BACKGROUND Field of the Disclosure

The present disclosure relates to an electronic apparatus and amanufacturing method thereof, and more particularly to a light-emittingapparatus and a manufacturing method thereof.

Description of Related Art

The transfer micro-device technique is applied in the process of newelectronic apparatuses. In the case of the process of a light emittingapparatus, the process of the light emitting apparatus includes thefollowing steps: providing a transfer stamp having a plurality oftransfer blocks; providing a plurality of light-emitting diode elementsto make the transfer block of the transfer stamp to contact thelight-emitting diode element and further pick up the light-emittingdiode element to be used; transferring the light-emitting diode elementto an adhesive layer of a receiving substrate by using the transferstamp; manufacturing an interconnection layer on the receiving substratecarrying the plurality of light-emitting diode elements such that thelight-emitting diode elements are electrically connected to the pads ofthe receiving substrate. However, the plurality of light-emitting diodeelements, the pads of the receiving substrate and the interconnectionlayer must be accurately aligned with each other so that thelight-emitting diode elements can be electrically connected to the padsof the receiving substrate, which makes it difficult for the yield rateof light-emitting apparatus to be improved.

SUMMARY OF THE DISCLOSURE

The disclosure provides a light-emitting apparatus and a manufacturingmethod thereof, which have high yield rate.

A light-emitting apparatus of the present disclosure includes asubstrate, a plurality of pads, a sacrificial pattern layer, alight-emitting diode element, and a plurality of connection patterns.The plurality of pads are disposed on the substrate. The sacrificialpattern layer is disposed on the substrate. The light-emitting diodeelement is disposed on the sacrificial pattern layer. The light-emittingdiode element includes a first type semiconductor layer, a second typesemiconductor layer with respect to the first type semiconductor layer,an active layer between the first type semiconductor layer and thesecond type semiconductor layer, and a plurality of electrodesrespectively electrically connected to the first type semiconductorlayer and the second type semiconductor layer. The plurality ofconnection patterns respectively disposed on at least one of theplurality of electrodes and the plurality of pads. The material of theplurality of connection patterns includes a hot fluidity conductivematerial, and the plurality of connection patterns cover sidewalls ofthe sacrificial pattern layer and are electrically connected to the atleast one of the plurality of pads and the plurality of electrodes.

A manufacturing method of a light-emitting apparatus of the presentdisclosure includes the steps of: providing a substrate and a pluralityof pads disposed on the substrate; forming a sacrificial material layeron the substrate to cover the plurality of pads; and disposing alight-emitting diode element on the sacrificial material layer, whereinthe light-emitting diode element includes a first type semiconductorlayer, a second type semiconductor layer, an active layer disposedbetween the first type semiconductor layer and the second typesemiconductor layer, and a plurality of electrodes respectivelyelectrically connected to the first type semiconductor layer and thesecond type semiconductor layer; forming a plurality of connectionpatterns disposed on at least one of the plurality of electrodes and theplurality of pads, and the material of the plurality of connectionpatterns includes a hot fluidity conductive material; patterning thesacrificial material layer to form a sacrificial pattern layer, andforming a plurality of gaps between the plurality of connection patternsand the plurality of pads or between the plurality of pads and theplurality of electrodes, wherein the sacrificial pattern layer exposesat least a portion of each of the plurality of pads; and performing aheating process to make the plurality of connection patterns to flow tobe electrically connected to the at least one of the plurality of padsand the plurality of electrodes.

In order to make the aforementioned features and advantages of thedisclosure more comprehensible, embodiments accompanying figures aredescribed in detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A to FIG. 1C are schematic cross-sectional views showing amanufacturing process of a light-emitting apparatus according to a firstembodiment of the present disclosure.

FIG. 2A to FIG. 2C are schematic cross-sectional views showing amanufacturing process of a light-emitting apparatus according to asecond embodiment of the present disclosure.

FIG. 3A to FIG. 3C are schematic cross-sectional views showing amanufacturing process of a light-emitting apparatus according to a thirdembodiment of the present disclosure.

FIG. 4A to FIG. 4C are schematic cross-sectional views showing amanufacturing process of a light-emitting apparatus according to afourth embodiment of the present disclosure.

FIG. 5A to FIG. 5C are schematic cross-sectional views showing amanufacturing process of a light-emitting apparatus according to a fifthembodiment of the present disclosure.

FIG. 6 is a schematic top view showing a light-emitting apparatusaccording to a fifth embodiment of the present disclosure.

FIG. 7A to FIG. 7F are schematic cross-sectional views showing amanufacturing process of a light-emitting apparatus according to a sixthembodiment of the present disclosure.

FIG. 8A to FIG. 8F are schematic top views showing a manufacturingprocess of a light-emitting apparatus according to a sixth embodiment ofthe present disclosure.

FIG. 9A to FIG. 9F are schematic cross-sectional views showing amanufacturing process of a light-emitting apparatus according to aseventh embodiment of the present disclosure.

FIG. 10A to FIG. 10F are schematic top views showing a manufacturingprocess of a light-emitting apparatus according to a seventh embodimentof the present disclosure.

DESCRIPTION OF EMBODIMENTS

In the accompanying drawings, thicknesses of layers, films, panels,regions and so on are exaggerated for clarity. Throughout thespecification, the same reference numerals in the accompanying drawingsdenote the same devices. It should be understood that when an elementsuch as a layer, film, region or substrate is referred to as being “onanother element” or “connected to another element,” it can be directlyon or connected to the other element, or intervening elements may alsobe present. In contrast, when an element is referred to as being“directly on” or “directly connected to” another element, there are nointervening elements present. As used herein, the term “connected” mayrefer to physically connected and/or electrically connected.Furthermore, “electrical connection” or “coupling” may be that otherelements are present between two elements.

The term “about,” “similar,” or “substantially” as used herein isinclusive of the stated value and means within an acceptable range ofdeviation for the particular value as determined by people havingordinary skill in the art, considering the measurement in question andthe error associated with measurement of the particular quantity (i.e.,the limitations of the measurement system) or the limitations of themanufacturing system. For instance, “about” may mean within one or morestandard deviations, or within, for example, ±30%, ±20%, ±10%, or ±5% ofthe stated value. Moreover, a relatively acceptable range of deviationor standard deviation may be chosen for the term “about,”“approximately,” or “substantially” as used herein based on opticalproperties, etching properties or other properties, instead of applyingone standard deviation across all the properties.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood bypersons of ordinary skill in the art. It will be further understood thatterms, such as those defined in commonly used dictionaries, should beinterpreted as having a meaning that is consistent with their meaning inthe context of the relevant art and the disclosure and will not beinterpreted in an idealized or overly formal sense unless expressly sodefined herein.

Exemplary embodiments of the disclosure are described with reference ofschematic cross-sectional views of the idealized embodiments. Therefore,a shape variation of the drawings as a result of a manufacturingtechnique and/or manufacturing tolerance, for example, is expected.Therefore, the embodiments of the disclosure should not be interpretedas being limited to specific shapes of the regions shown in the drawingsbut may include a shape deviation caused during manufacture, forexample. For example, a flat area shown in the figures or describedherein may practically have rough and/or non-linear characteristics.Moreover, an acute angle shown in the drawings can practically berounded. Therefore, the shapes shown in the figures are substantiallyschematic, and the shapes therein are not intended to represent accurateshapes, and are not intended to serve as limitations of the claims.

Reference will now be made in detail to the exemplary embodiments.Examples of exemplary embodiments are described in the accompanyingdrawings. Wherever possible, the same reference symbols are used todenote the same or similar parts in the drawings and the description.

FIG. 1A to FIG. 1C are schematic cross-sectional views showing amanufacturing process of a light-emitting apparatus according to a firstembodiment of the present disclosure.

Referring to FIG. 1A, first, an active device substrate A is provided.The active device substrate A includes a substrate 110 and a pluralityof pads 130 a and 130 b disposed on the substrate 110. In thisembodiment, the material of the pads 130 a and 130 b is, for example,metal, but the disclosure is not limited thereto. In this embodiment,the active device substrate A further includes a driving circuit layer120 electrically connected to the pads 130 a and 130 b. For example, thedriving circuit layer 120 may include a data line (not shown), a scanline (not shown), a power line (not shown), a common line (not shown), afirst transistor (not shown) and a second transistor (not shown). Thefirst transistor has a first end, a second end and a control end, andthe second transistor also has a first end, a second end and a controlend. The first end of the first transistor is electrically connected tothe data line, the control end of the first transistor is electricallyconnected to the scan line, the second end of the first transistor iselectrically connected to the control end of the second transistor, andthe first end of the second transistor is electrically connected to thepower line. The second end of the second transistor is electricallyconnected to one of the pads 130 a and 130 b, and the other of the pads130 a and 130 b is electrically connected to the common line. However,the present disclosure is not limited thereto, and in other embodiments,the driving circuit layer 120 may be of other forms.

Referring to FIG. 1A, then, a sacrificial material layer 140 is formedon the substrate 110 to cover the plurality of pads 130 a and 130 b. Thesacrificial material layer 140 can also be referred to as a bondinglayer. For example, in this embodiment, the material of the sacrificialmaterial layer 140 may be a photoresist, a heat curing adhesive or othersuitable material.

Referring to FIG. 1A, next, a light-emitting diode element 150 isdisposed on the sacrificial material layer 140. The light-emitting diodeelement 150 is bonded to the active device substrate A through thesacrificial material layer 140. The light-emitting diode element 150includes a first type semiconductor layer 152 a, a second typesemiconductor layer 152 b, an active layer 154 disposed between thefirst type semiconductor layer 152 a and the second type semiconductorlayer 152 b, and a plurality of electrodes 156 a and 156 b electricallyconnected to the first type semiconductor layer 152 a and the secondtype semiconductor layer 152 b respectively.

In the present embodiment, the plurality of electrodes 156 a and 156 bare located on the same side of the first type semiconductor layer 152a. That is, the light-emitting diode element 150 is a horizontallight-emitting diode. In addition, the light-emitting diode element 150further includes an insulating layer 151 disposed on the first typesemiconductor layer 152 a and the second type semiconductor layer 152 band having a plurality of openings 151 a and 151 b respectivelyoverlapping the first type semiconductor layer 152 a and the second typesemiconductor layer 152 b, wherein the plurality of electrodes 156 a and156 b are electrically connected to the first type semiconductor layer152 a and the second type semiconductor layer 152 b through theplurality of openings 151 a and 151 b, respectively.

It should be noted that the first embodiment of the present disclosurefurther includes a plurality of connection patterns 158 a and 158 b, andthe materials of the plurality of connection patterns 158 a, 158 binclude hot fluidity conductive materials. The hot fluidity conductivematerials can flow after being heated. The temperature resistance of theactive device substrate A and the sacrificial material layer 140 ishigher than the temperature resistance of the hot fluidity conductivematerial. For example, in the present embodiment, the material of thehot fluidity conductive material may include indium (In), tin (Sn),other suitable materials, or a combination thereof, but the disclosureis not limited thereto.

The plurality of connection patterns 158 a and 158 b can be forming onat least one of the plurality of electrodes 156 a and 156 b and theplurality of plurality of pads 130 a and 130 b. In other words, theplurality of connection patterns 158 a and 158 b can be disposed betweenof the plurality of electrodes 156 a and 156 b and the plurality ofplurality of pads 130 a and 130 b, and may be having three models. Firstmodel, the plurality of connection patterns 158 a and 158 b are as oneportion of the light-emitting diode element 150. Second model, theplurality of connection patterns 158 a and 158 b are respectivelydisposed on the plurality of pads 130 a and 130 b. Third model, oneportion of the plurality of connection patterns 158 a and 158 b arerespectively disposed on the plurality of pads 130 a and 130 b, andanother portion of the plurality of connection patterns 158 a and 158 bare as one portion of the light-emitting diode element 150. Embodimentsof the present disclosure are description below with the first model asa preferably exemplary embodiment, but not limited thereto. Other modelsof the embodiments can be analogous. The plurality of connectionpatterns 158 a and 158 b of the light-emitting diode element 150 arerespectively disposed on the plurality of electrodes 156 a and 156 b.For example, in the embodiment, the connection patterns 158 a and 158 bare not only disposed on the electrodes 156 a and 156 b, but alsodisposed on the stacked sidewall constituted by the first typesemiconductor layer 152 a, the second type semiconductor layer 152 b,and the active layer 154, but the disclosure is not limited thereto.

Referring to FIG. 1A and FIG. 1B, next, the sacrificial material layer140 in the one model is patterned to form the sacrificial pattern layer142, and a plurality of gaps g are formed between the plurality ofconnection patterns 158 a and 158 b and the plurality of pads 130 a and130 b, wherein the sacrificial pattern layer 142 exposes at least aportion of each of the plurality of pads 130 a and 130 b. When in thesecond model, the plurality of gaps g are formed between the pluralityof electrodes 156 a and 156 b and the plurality of pads 130 a and 130 b.In other words, the plurality of gaps g are formed between the pluralityof connection patterns 158 a and 158 b and the plurality of pads 130 aand 130 b or between the plurality of pads 130 a and 130 b and theplurality of electrodes 156 a and 156 b.

For example, in the embodiment, the sacrificial material layer 140 isover-etched by using the light-emitting diode element 150 as a mask toform the sacrificial pattern layer 142. There are a plurality of gaps gbetween the sidewall 142 a of the sacrificial pattern layer 142, theconnection patterns 158 a and 158 b, and the plurality of pads 130 a and130 b. In this embodiment, the vertical projection of the sacrificialpattern layer 142 on the substrate 110 may be within a verticalprojection of the light-emitting diode element 150 on the substrate 110,and the area of the vertical projection of the sacrificial pattern layer142 on the substrate 110 may be less than the area of the verticalprojection of the light-emitting diode element 150 on the substrate 110,but the disclosure is not limited thereto.

Referring to FIG. 1B and FIG. 1C, a heating process is then performed tomake the plurality of connection patterns 158 a and 158 b becomeflowable, and the flowable connection patterns 158 a and 158 b flowdownward by gravity, and are respectively electrically connected to theat least one of the plurality to pads 130 a and 130 b and the pluralityof electrodes 156 a and 156 b. The above heating process may be localheating or global heating depending on actual needs. For example, localheating may be performed by using laser welding; global heating may beperformed by using a heating oven or a hot plate; however, the presentdisclosure is not limited thereto. At the present stage, thelight-emitting apparatus 100 of the present embodiment is completed. Inthe present embodiment, the light-emitting apparatus 100 is, forexample, a display apparatus. However, the present disclosure is notlimited thereto. In other embodiments, the light-emitting apparatus 100may also be an electronic apparatus that provides an illumination beam,such as but not limited to: a backlight.

It should be mentioned that, in this embodiment, the sacrificialmaterial layer 140 under the light-emitting diode element 150 ispatterned by using the light-emitting diode element 150 as a mask toform the sacrificial pattern layer 142; then, the connection patterns158 a and 158 b inherently belonging to the light-emitting diode element150 are respectively flowed onto the pads 130 a and 130 b of the activedevice substrate A to electrically connect the light-emitting diodeelement 150 and the active device substrate A. In this manner, thealignment accuracy requirement between the plurality of light-emittingdiode elements 150 that are mass transferred and the plurality of pads130 a and 130 b of the active device substrate A can be reduced, therebyimproving the yield rate of the light-emitting apparatus 100.

Referring to FIG. 1C, the light-emitting apparatus 100 includes asubstrate 110, a plurality of pads 130 a and 130 b, a sacrificialpattern layer 142, and a light-emitting diode element 150. The pluralityof pads 130 a and 130 b are disposed on the substrate 110. Thesacrificial pattern layer 142 is at least disposed in a region R betweenthe plurality of pads 130 a and 130 b and has a sidewall 142 a. Thelight-emitting diode element 150 is disposed on the sacrificial patternlayer 142. The sacrificial pattern layer 142 is disposed between thefirst type semiconductor layer 152 a of the light-emitting diode element150 and the substrate 110. The connection patterns 158 a and 158 b coverthe sidewall 142 a of the sacrificial pattern layer 142 and areelectrically connected to the at least one of the plurality of pads 130a and 130 b and the plurality of electrodes 156 a and 156 b. In thefirst model, the connection patterns 158 a and 158 b cover the sidewall142 a of the sacrificial pattern layer 142 and are electricallyconnected to the at least one of the plurality of pads 130 a and 130 b,but not limited thereto. In this embodiment, the connection patterns 158a and 158 b may be in contact with the sidewall 142 a of the sacrificialpattern layer 142 and the surfaces 130 a 1 and 130 b 1 of the pluralityof pads 130 a and 130 b, but the disclosure is not limited thereto.

In the present embodiment, the active layer 154 of the light-emittingdiode element 150 may be disposed between the plurality of electrodes156 a and 156 b of the light-emitting diode element 150 and thesacrificial pattern layer 142. That is, in the present embodiment, theplurality of electrodes 156 a and 156 b of the light-emitting diodeelement 150 may optionally face upward. However, the present disclosureis not limited thereto, and according to other embodiments, theplurality of electrodes 156 a and 156 b of the light-emitting diodeelement 150 may face downward, as exemplified below with other FIG. 2Athrough FIG. 2C.

FIG. 2A to FIG. 2C are schematic cross-sectional views showing amanufacturing process of a light-emitting apparatus according to asecond embodiment of the present disclosure. The manufacturing processof a light-emitting apparatus 100A of the second embodiment is similarto the manufacturing process of the light-emitting apparatus 100 of thefirst embodiment, and the main difference between the two is that themanner in which the light-emitting diode elements 150 are disposed onthe active device substrate A is different, which will be specificallydescribed with reference to FIG. 2A to FIG. 2C.

Referring to FIG. 2A, first, an active device substrate A is provided.The active device substrate A includes the substrate 110 and theplurality of pads 130 a and 130 b disposed on the substrate 110. In thepresent embodiment, a distance H1 between the surface 130 a 1 of the pad130 a and the substrate 110 may be optionally greater than the distanceH2 between the surface 130 b 1 of the pad 130 b and the substrate 110.That is, the thickness D1 of the pad 130 a may be greater than thethickness D2 of the pad 130 b.

Referring to FIG. 2A, then the sacrificial material layer 140 is formedon the substrate 110 to cover the plurality of pads 130 a and 130 b.Thereafter, the light-emitting diode element 150 is disposed on thesacrificial material layer 140. The height difference between theplurality of electrodes 156 a and 156 b of the light-emitting diodeelement 150 can be compensated by the pads 130 a and 130 b havingdifferent thicknesses. In this manner, the thickness of a portion of thesacrificial material layer 140 sandwiched between the connection pattern158 a and the pad 130 a can be substantially equal to the thickness of aportion of the sacrificial material layer 140 sandwiched between theconnection pattern 158 b and the pad 130 b to facilitate subsequentpatterning of the sacrificial material layer 140.

Referring to FIG. 2A and FIG. 2B, next, the sacrificial material layer140 is patterned to form the sacrificial pattern layer 142, and aplurality of gaps g are formed between the plurality of connectionpatterns 158 a and 158 b and the plurality of pads 130 a and 130 b orbetween the plurality of pads 130 a and 130 b and the plurality ofelectrodes 156 a and 156 b. When in the first model, the plurality ofgaps g are formed between the plurality of connection patterns 158 a and158 b and the plurality of pads 130 a and 130 b. When in the secondmodel, the plurality of gaps g are formed between the plurality of pads130 a and 130 b and the plurality of electrodes 156 a and 156 b. Whereinthe sacrificial pattern layer 142 exposes at least a portion of each ofthe plurality of pads 130 a and 130 b. As shown in FIG. 2A, in theembodiment, since the thickness of the portion of the sacrificialmaterial layer 140 sandwiched between the connection pattern 158 a andthe pad 130 a is substantially equal to the thickness of the portion ofthe sacrificial material layer 140 sandwiched between the connectionpattern 158 b and the pad 130 b, when the sacrificial material layer 140is over-etched by using the light-emitting diode element (LED) 150 as amask, a plurality of gaps g can be easily formed between the connectionpattern 158 a and the pad 130 a and between the connection pattern 158 band the pad 130 b without easily occurring undesirable phenomena (forexample, but not limited to, a gap g has been formed between theconnection pattern 158 b and the pad 130 b, but a gap g has not beenformed between the connection pattern 158 a and the pad 130 a).

Referring to FIG. 2B and FIG. 2C, a heating process is then performed tomake the plurality of connection patterns 158 a and 158 b becomeflowable, and the flowable connection patterns 158 a and 158 b flowdownward by gravity, and are respectively electrically connected to theplurality of pads 130 a and 130 b in the first model. When in the secondmodel, a heating process is then performed to make the plurality ofconnection patterns 158 a and 158 b become flowable, and the flowableconnection patterns 158 a and 158 b flow upward by transfer LED's 150force, and are respectively electrically connected to the plurality ofelectrodes 156 a and 156 b. At the present stage, the light-emittingapparatus 100A of the present embodiment is completed.

Referring to FIG. 2C, the light-emitting apparatus 100A of the presentembodiment is similar to the light-emitting apparatus 100 of the firstembodiment. The main difference between the two is that the electrodes156 a and 156 b of the light-emitting diode element 150 are disposedbetween the active layer 154 of the light-emitting diode element 150 andthe sacrificial pattern layer 142. That is, in the present embodiment,the plurality of electrodes 156 a and 156 b of the light-emitting diodeelement 150 may optionally face downward. In addition, in the presentembodiment, the sacrificial pattern layer 142 not only contacts theconnection pattern 142 but also contacts the insulating layer 151between the plurality of electrodes 156 a and 156 b of thelight-emitting diode element 150.

FIG. 3A to FIG. 3C are schematic cross-sectional views showing amanufacturing process of a light-emitting apparatus according to a thirdembodiment of the present disclosure. The manufacturing process of alight-emitting apparatus 100B of the third embodiment is similar to themanufacturing process of the light-emitting apparatus 100A of the secondembodiment, and the main difference between the two is that the mannerof compensating for the height difference between the plurality ofelectrodes 156 a and 156 b of the light-emitting diode element 150 inthe third embodiment is different from the manner of compensating forthe height difference between the plurality of electrodes 156 a and 156b of the light-emitting diode element 150 in the second embodiment,which will be specifically described below with reference to FIG. 3A toFIG. 3C.

Referring to FIG. 3A, first, the active device substrate A is provided.The active device substrate A includes the substrate 110 and theplurality of pads 130 a and 130 b disposed on the substrate 110.Different from the second embodiment, the active device substrate A ofthe present embodiment further includes an auxiliary conductive pattern170 disposed on the pad 130 a and electrically connected to the pad 130a. Specifically, the active device substrate A further includes a firstdielectric layer 160. The first dielectric layer 160 is disposed on theplurality of pads 130 a and 130 b and has a first contact via 162. Theauxiliary conductive pattern 170 is disposed on the first dielectriclayer 160 and is electrically connected to the pad 130 a through thefirst contact via 162. In addition, the first dielectric layer 160 alsohas a second contact via 164 that overlaps the pad 130 b.

Referring to FIG. 3A, the sacrificial material layer 140 is formed onthe substrate 110 to cover the plurality of pads 130 a and 130 b. In thepresent embodiment, the sacrificial material layer 140 is disposed onthe auxiliary conductive pattern 170 and the first dielectric layer 160,and is disposed above the plurality of pads 130 a and 130 b. Then, thelight-emitting diode element 150 is disposed on the sacrificial materiallayer 140. The arrangement of the auxiliary conductive pattern 170 cancompensate for the height difference between the plurality of electrodes156 a and 156 b of the light-emitting diode element 150. That is, thethickness of the portion of the sacrificial material layer 140sandwiched between the connection pattern 158 a and the auxiliaryconductive pattern 170 may be substantially equal to the thickness ofthe portion of the sacrificial material layer 140 sandwiched between theconnection pattern 158 b and the pad 130 b to facilitate subsequentpatterning of the sacrificial material layer 140.

Referring to FIG. 3A and FIG. 3B, then the sacrificial material layer140 is patterned to form the sacrificial pattern layer 142, and theplurality of gaps g are formed between the plurality of connectionpatterns 158 a and 158 b of the light-emitting diode element 150 and theauxiliary conductive pattern 170 and the pad 130 b, wherein thesacrificial pattern layer 142 exposes the auxiliary conductive patterns170 and at least a portion of each of and the pads 130 b. As shown inFIG. 3A, in the embodiment, since the thickness of the portion of thesacrificial material layer 140 sandwiched between the connection pattern158 a and the auxiliary conductive pattern 170 is substantially equal tothe thickness of the portion of the sacrificial material layer 140between the connection pattern 158 b and the pad 130 b, when thesacrificial material layer 140 is over-etched by using thelight-emitting diode element 150 as a mask, the plurality of gaps g canbe easily formed between the connection pattern 158 a and the pad 130 aand between the connection pattern 158 b and the pads 130 b withouteasily occurring undesirable phenomena (for example, but not limited to,a gap g has been formed between the connection pattern 158 b and the pad130 b, but a gap g has not been formed between the connection pattern158 a and the pad 130 a).

Referring to FIG. 3B and FIG. 3C, then a heating process is performed tomake the plurality of connection patterns 158 a and 158 b flowable, andthe flowable connection patterns 158 a and 158 b flow downward bygravity, and are electrically connected to the auxiliary conductivepattern 170 and the pad 130 b respectively. In the present embodiment,the connection pattern 158 a including the hot fluidity conductivematerial is in contact with the auxiliary conductive pattern 170, andthe auxiliary conductive pattern 170 can be regarded as a pad. Thesacrificial pattern layer 142 is at least disposed in a region R betweenthe auxiliary conductive pattern 170 and the pad 130 b. In addition, inthe embodiment, the other connection pattern 158 b is electricallyconnected to the second contact via 164 of the first dielectric layer160 and the pad 130 b. At the present stage, the light-emittingapparatus 100B of the present embodiment is completed.

FIG. 4A to FIG. 4C are schematic cross-sectional views showing amanufacturing process of a light-emitting apparatus according to afourth embodiment of the present disclosure. The manufacturing processof a light-emitting apparatus 100C of the fourth embodiment is similarto the manufacturing process of the light-emitting apparatus 100B of thethird embodiment, and the main difference between the two is that themanner of compensating for the height difference between the pluralityof electrodes 156 a and 156 b of the light-emitting diode element 150 inthe fourth embodiment is different from the manner of compensating forthe height difference between the plurality of electrodes 156 a and 156b of the light-emitting diode element 150 in the third embodiment, whichwill be described below with reference to FIG. 4A to FIG. 4C.

Referring to FIG. 4A, first, the active device substrate A is provided.The active device substrate A includes the substrate 110 and theplurality of pads 130 a and 130 b disposed on the substrate 110. Unlikethe third embodiment, the active device substrate A of the presentembodiment does not include the auxiliary conductive pattern 170.

Referring to FIG. 4A, the sacrificial material layer 140 is formed onthe substrate 110 to cover the plurality of pads 130 a and 130 b. Then,the light-emitting diode element 150 is disposed on the sacrificialmaterial layer 140. Different from the third embodiment, thelight-emitting diode element 150 of the present embodiment is differentfrom the light-emitting diode element 150 of the third embodiment.Specifically, the light-emitting diode element 150 of the presentembodiment further includes an auxiliary electrode 159 disposed on oneof the electrodes 156 a of the light-emitting diode element 150 andelectrically connected to the electrode 156 a. When the light-emittingdiode element 150 is disposed on the sacrificial material layer 140, thesurface 159 a of the pad 130 a of the auxiliary electrode 159 facing theactive device substrate A can be substantially coplanar with the surface156 b 1 of the pad 130 b of the other electrode 156 b facing of theactive device substrate A. The connection pattern 158 a and theconnection pattern 158 b are respectively disposed on the surface 159 aof the auxiliary electrode 159 and the surface 156 b 1 of the electrode156 b, and are electrically connected to the auxiliary electrode 159 andthe electrode 156 b, respectively. Since the connection pattern 158 a isdisposed on the auxiliary electrode 159 for compensating for the heightdifference between the electrodes 156 a and 156 b, the thickness of theportion of the sacrificial material layer 140 sandwiched between theconnection pattern 158 a and the pad 130 a can be substantially equal tothe thickness of the portion of the sacrificial material layer 140between the connection pattern 158 b and the pad 130 b to facilitatesubsequent patterning of the sacrificial material layer 140.

Referring to FIG. 4A and FIG. 4B, next, the sacrificial material layer140 is patterned to form the sacrificial pattern layer 142, and theplurality of gaps g are formed between the plurality of connectionpatterns 158 a and 158 b of the light-emitting diode element 150 and theplurality of pads 130 a and 130 b, wherein the sacrificial pattern layer142 exposes at least a portion of each of the plurality of pads 130 aand 130 b. As shown in FIG. 4A, in the present embodiment, the auxiliaryelectrode 159 of the light-emitting diode element 150 compensates forthe height difference between the electrode 156 a and the electrode 156b, such that the thickness of the portion of the sacrificial materiallayer 140 sandwiched between the connection pattern 158 a and the pad130 a is substantially equal to the thickness of the portion of thesacrificial material layer 140 sandwiched between the connection pattern158 b and the pad 130 b. Therefore, when the sacrificial material layer140 is over-etched by using the light-emitting diode element 150 as amask, the plurality of gaps g can be easily formed between theconnection pattern 158 a and the pad 130 a and between the connectionpattern 158 b and the pad 130 b without easily occurring undesirablephenomena (for example, but not limited to, a gap g has been formedbetween the connection pattern 158 b and the pad 130 b, but a gap g hasnot been formed between the connection pattern 158 a and the pad 130 a).

Referring to FIG. 4B and FIG. 4C, then a heating process is performed tomake the plurality of connection patterns 158 a and 158 b becomeflowable, and the flowable connection patterns 158 a and 158 b flowdownward by gravity, and are electrically connected to the plurality ofpads 130 a and 130 b respectively. At the present stage, thelight-emitting apparatus 100C of the present embodiment is completed. Insome embodiment, a distance between a surface of one of the pads 130 aand 130 b in contact with one of the connection patterns 158 a and 158 band the substrate 110 is substantially equal to a distance between asurface of another of the pads 130 a and 130 b in contact with anotherof the connection patterns 158 a and 158 b and the substrate 110.

The first to fourth embodiments describe the manufacturing process ofone pixel of the light-emitting apparatuses 100, 100A to 100C as anexample. Those having ordinary skill in the art should be able tounderstand that the manufacturing process of the one pixel can be usedto simultaneously manufacture a plurality of pixels, which will beexemplified below with reference to FIG. 5A to FIG. 5C and FIG. 6.

FIG. 5A to FIG. 5C are schematic cross-sectional views showing amanufacturing process of a light-emitting apparatus according to a fifthembodiment of the present disclosure. FIG. 6 is a schematic top viewshowing a light-emitting apparatus according to a fifth embodiment ofthe present disclosure. FIG. 5C corresponds to the cross-sectional lineI-I′ taken from FIG. 6. FIG. 6 depicts the substrate 110 and thelight-emitting diode element 150 of FIG. 5C, while the other componentsof FIG. 5C are omitted.

Referring to FIG. 5A, first, the active device substrate A is provided.The active device substrate A includes the substrate 110 and a pluralityof pad sets 130 disposed on the substrate 110. Each pad set 130 includesthe plurality of pads 130 a and 130 b. Next, the sacrificial materiallayer 140 is formed on the substrate 110 to cover the plurality of padsets 130. Then, the plurality of light-emitting diode elements 150 aredisposed on the sacrificial material layer 140. The plurality oflight-emitting diode elements 150 are bonded to the active devicesubstrate A through the sacrificial material layer 140.

Referring to FIG. 5A and FIG. 5B, next, the sacrificial material layer140 is patterned to form the sacrificial pattern layer 142, and theplurality of gaps g are formed between the plurality of connectionpatterns 158 a and 158 b and the plurality of pads 130 a and 130 b,wherein the sacrificial pattern layer 142 exposes at least a portion ofeach of the plurality of pads 130 a and 130 b.

Referring to FIG. 5B, FIG. 5C FIG. 6, then a heating process isperformed to make the plurality of connection patterns 158 a and 158 bof the plurality of light-emitting diode elements 150 become flowable,and the flowable connection patterns 158 a and 158 b flow downward bygravity, and are electrically connected to the plurality of pads 130 aand 130 b respectively. At the present stage, the light-emittingapparatus 100D of the present embodiment is completed.

The first to the fifth embodiments describe the fabrication of thelight-emitting apparatuses 100, 100A to 100D directly by using theconnection patterns 158 a and 158 b including the hot fluidityconductive material. However, the present disclosure is not limitedthereto, and the light-emitting diode element 150 of the connectionpatterns 158 a and 158 b including the hot fluidity conductive materialmay also be used to repair the completed light-emitting apparatus, whichwill be exemplified with reference to FIG. 7A to FIG. 7F, FIG. 8A toFIG. 8F, FIG. 9A to FIG. 9F and FIG. 10A to FIG. 10F.

FIG. 7A to FIG. 7F are schematic cross-sectional views showing amanufacturing process of a light-emitting apparatus according to a sixthembodiment of the present disclosure. FIG. 8A to FIG. 8F are schematictop views showing a manufacturing process of a light-emitting apparatusaccording to a sixth embodiment of the present disclosure. FIG. 8A toFIG. 8F correspond to the cross-sectional lines I-I′ and II-II′ takenfrom FIG. 7A to FIG. 7F, respectively. FIG. 8A to FIG. 8F illustrate thelight-emitting diode element 150, the interconnection patterns 182 and184, and the substrate 110 of FIG. 7A to FIG. 7F, and other componentsin FIG. 7A to FIG. 7F are omitted.

Referring to FIG. 7A and FIG. 8A, FIG. 7A and FIG. 8A illustrate alight-emitting apparatus manufactured by a conventional method.Specifically, a light-emitting apparatus that has been completed byusing a conventional method includes an active device substrate A, aplurality of light-emitting diode elements 150-1 and 150-2, and aplurality of interconnection patterns 182 and 184.

Referring to FIG. 7A and FIG. 8A, after the light-emitting apparatus hasbeen completed by the conventional method, then the light-emittingapparatus is detected, and it is found that the light-emitting diodeelement 150-2 is abnormal and/or the electrical connection with theactive device substrate A is poor. Referring to FIG. 7A, FIG. 7B, FIG.8A, and FIG. 8B, thereafter the light-emitting diode element 150-2 isremoved. When the light-emitting diode element 150-2 is removed, aportion of the interconnection pattern 182 disposed on thelight-emitting diode element 150-2 and a portion of the interconnectionpattern 184 disposed on the light-emitting diode element 150-2 areremoved along with the light-emitting diode element 150-2, and anotherportion of the interconnection pattern 182 disposed on the seconddielectric layer 190 and another portion of the interconnection pattern184 disposed on the second dielectric layer 190 are left on thesubstrate 110 as shown in FIG. 7B and FIG. 8B.

Referring to FIG. 7C and FIG. 8C, next, the sacrificial material layer140 is formed on the substrate 110 to cover the plurality of pads 130 aand 130 b. In this embodiment, the sacrificial material layer 140 isformed on a portion of the second dielectric layer 190 overlapping theoriginal light-emitting diode element 150-2 and the partialinterconnection pattern 182 and the partial interconnection pattern 184on both sides of the light-emitting diode element 150-2.

Referring to FIG. 7D and FIG. 8D, next, the light-emitting diode element150-3 is disposed on the sacrificial material layer 140. Thelight-emitting diode element 150-3 is bonded to the active devicesubstrate A through the sacrificial material layer 140. Thelight-emitting diode element 150-3 also includes the plurality ofconnection patterns 158 a and 158 b.

Referring to FIG. 7D, FIG. 7E, FIG. 8D, and FIG. 8E, then thesacrificial material layer 140 is patterned to form the sacrificialpattern layer 142, and the plurality of gaps g are formed between theplurality of connection patterns 158 a and 158 b of the light-emittingdiode element 150 and the partial interconnection patterns 182 and 184,wherein the sacrificial pattern layer 142 exposes at least a portion ofeach of the partial interconnection patterns 182 and 184. For example,in the embodiment, the sacrificial material layer 140 is over-etched byusing the light-emitting diode element 150-3 as a mask to form thesacrificial pattern layer 142. When the sacrificial material layer 140is subjected to an over-etching process, there are the plurality of gapsg between the sidewall 142 a of the sacrificial pattern layer 142 andthe interconnection patterns 182 and 184.

Referring to FIG. 7F and FIG. 8F, next, a heating process is performedto make the plurality of connection patterns 158 a and 158 b becomeflowable, and the flowable connection patterns 158 a and 158 b flowdownward by gravity, and are electrically connected to theinterconnection patterns 182 and 184 respectively remained on thesubstrate 110. In the present embodiment, the connection patterns 158 aand 158 b of the light-emitting diode element 150-3 are in contact withand electrically connected to the interconnection patterns 182 and 184.The interconnection patterns 182 and 184 can also be regarded as pads.The sacrificial pattern layer 142 is at least disposed in a region Rbetween the interconnection pattern 182 and the interconnection pattern184. The connection patterns 158 a and 158 b of the light-emitting diodeelement 150-3 are electrically connected to the pads 130 a and 130 bthrough the interconnection patterns 182 and 184. At the present stage,the repaired light-emitting apparatus 100E is completed.

It should be noted that in the present embodiment, the electrode 156 bof the light-emitting diode element 150-1 and the electrode 156 b of thelight-emitting diode element 150-3 for repair are electrically connectedto each other. That is to say, the normal light-emitting diode element150-1 and the light-emitting diode element 150-3 for repair belong tothe same pixel. However, the present disclosure is not limited thereto,and according to other embodiments, the electrode 156 b of the normallight-emitting diode element 150-1 and the electrode 156 b of thelight-emitting diode element 150-3 for repair are also electricallyindependent from each other; that is, the normal light-emitting diodeelement 150-1 and the light-emitting diode element 150-3 for repair mayalso belong to different pixels.

As shown in FIG. 7F and FIG. 8F, in the present embodiment, thelight-emitting diode element 150-3 for replacing the originallight-emitting diode element 150-2 is disposed at the position where theoriginal light-emitting diode element 150-2 is disposed. That is, in thepresent embodiment, the new light-emitting diode element 150-3 overlapsthe pads 130 a and 130 b. However, the present disclosure is not limitedthereto. In other embodiments, the light-emitting diode element 150-3for replacing the original light-emitting diode element 150-2 may not bedisposed at the position where the original light-emitting diode element150-2 is disposed, which will be exemplified below with reference toFIG. 9A to FIG. 9F and FIG. 10A to FIG. 10F.

FIG. 9A to FIG. 9F are schematic cross-sectional views showing amanufacturing process of a light-emitting apparatus according to aseventh embodiment of the present disclosure. FIG. 10A to FIG. 10F areschematic top views showing a manufacturing process of a light-emittingapparatus according to a seventh embodiment of the present disclosure.FIG. 9A to FIG. 9F correspond to the cross-sectional lines I-I′ andII-II′ taken from FIG. 10A to FIG. 10F, respectively. FIG. 10A to FIG.10F illustrate the light-emitting diode element 150, the interconnectionpatterns 182 and 184, and the substrate 110 in FIG. 9A to FIG. 9F, whileother components in FIG. 9A to FIG. 9F are omitted.

Referring to FIG. 9A and FIG. 10A, first, the active device substrate Ais provided. The active device substrate A includes the substrate 110,the driving circuit layer 120 disposed on the substrate 110, theplurality of pads 130 a and 130 b electrically connected to the drivingcircuit layer 120, and the second dielectric layer 190 disposed on theplurality of pads 130 a and 130 b. The second dielectric layer 190 hascontact vias 192 and 194 that overlap the plurality of pads 130 a and130 b, respectively. The light-emitting diode element 150-1 is disposedon the second dielectric layer 190. The plurality of interconnectionpatterns 182 and 184 are respectively disposed on the plurality ofelectrodes 156 a and 156 b of the light-emitting diode element 150-1,and are electrically connected to the plurality of pads 130 a and 130 brespectively through the contact vias 192 and 194 of the seconddielectric layer 190. Specifically, in the present embodiment, theinterconnection patterns 182 and 184 have portions 182 a and 184 a thatextend beyond the pads 130 a and 130 b without overlapping the pads 130a and 130 b.

Referring to FIG. 9A and FIG. 10A, after the light-emitting apparatus ismanufactured by using the conventional method, then the light-emittingapparatus is detected, and it is found that the light-emitting diodeelement 150-1 is abnormal and/or the electrical connection with theactive device substrate A is poor. Referring to FIG. 9A, FIG. 9B, FIG.10A, and FIG. 10B, then the light-emitting diode element 150-1 isremoved.

Referring to FIG. 9C and FIG. 10C, the sacrificial material layer 140 isformed on the substrate 110 to cover a portion 182 a of theinterconnection pattern 182 that does not overlap the pads 130 a and 130b and a portion 184 a of the interconnection pattern 184 that does notoverlap the pad 130 b.

Referring to FIG. 7D and FIG. 8D, next, the light-emitting diode element150-3 is disposed on the sacrificial material layer 140. Thelight-emitting diode element 150-3 is bonded to the active devicesubstrate A through the sacrificial material layer 140. Thelight-emitting diode element 150-3 also includes the plurality ofconnection patterns 158 a and 158 b.

Referring to FIG. 9D, FIG. 9E, FIG. 9D, and FIG. 9E, then thesacrificial material layer 140 is patterned to form the sacrificialpattern layer 142, and the plurality of gaps g are formed between theplurality of connection patterns 158 a and 158 b of the light-emittingdiode element 150 and the partial interconnection patterns 182 a and 184a, wherein the sacrificial pattern layer 142 exposes at least a portionof each of the partial interconnection patterns 182 a and 184 a.

Referring to FIG. 9F and FIG. 10F, thereafter a heating process isperformed to make the plurality of connection patterns 158 a and 158 bbecome flowable, and the flowable connection patterns 158 a and 158 bflow downward by gravity, and are electrically connected to a portion182 a of the interconnection pattern 182 not overlapping the pads 130 aand 130 b and a portion 184 a of the interconnection pattern 184 notoverlapping the pad 130 b respectively. In the present embodiment, theconnection patterns 158 a and 158 b of the light-emitting diode element150-3 are in contact with and electrically connected to a portion 182 aof the interconnection pattern 182 and a portion 184 a of theinterconnection pattern 184. A portion 182 a of the interconnectionpattern 182 and a portion 184 a of the interconnection pattern 184 canalso be regarded as a pad. The sacrificial pattern layer 142 is at leastdisposed in a region R between the portion 182 a of the interconnectionpattern 182 and the portion 184 a of the interconnection pattern 184.The connection patterns 158 a and 158 b of the light-emitting diodeelement 150-3 are electrically connected to the pads 130 a and 130 bthrough the interconnection patterns 182 and 184. At the present stage,the repaired light-emitting apparatus 100F is completed.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the disclosed embodimentswithout departing from the scope or spirit of the disclosure. In view ofthe foregoing, it is intended that the disclosure covers modificationsand variations provided that they fall within the scope of the followingclaims and their equivalents.

What is claimed is:
 1. A lighting-emitting apparatus, comprising: asubstrate; a plurality of pads disposed on the substrate; a sacrificialpattern layer, disposed on the substrate and having an outermostsidewall; and a light-emitting diode element, disposed on thesacrificial pattern layer, wherein the light-emitting diode elementcomprises: a first type semiconductor layer; a second type semiconductorlayer opposite to the first type semiconductor layer; an active layerdisposed between the first type semiconductor layer and the second typesemiconductor layer; a plurality of electrodes electrically connected tothe first type semiconductor layer and the second type semiconductorlayer respectively; and a plurality of connection patterns respectivelydisposed on at least one of the electrodes and the pads, whereinmaterials of the connection patterns comprise hot fluidity conductivematerials, and the connection patterns cover the outermost sidewall ofthe sacrificial pattern layer and are electrically connected to the atleast one of the pads and the electrodes, wherein the sacrificialpattern layer is located between the connection patterns, and thesacrificial pattern layer is overlapped with the pads in a normaldirection of the substrate.
 2. The light-emitting apparatus according toclaim 1, wherein the active layer of the light-emitting diode element isdisposed between the electrodes of the light-emitting diode element andthe sacrificial pattern layer.
 3. The light-emitting apparatus accordingto claim 1, wherein the electrodes of the light-emitting diode elementare disposed between the active layer of the light-emitting diodeelement and the sacrificial pattern layer.
 4. The light-emittingapparatus according to claim 3, wherein the light-emitting diodecomponent further comprises: an insulating layer, disposed on the firsttype semiconductor layer and the second type semiconductor layer andhaving a plurality of openings respectively overlapping the first typesemiconductor layer and the second type semiconductor layer, wherein theelectrodes are respectively electrically connected to the first typesemiconductor layer and the second type semiconductor layer through theopenings of the insulating layer; wherein the sacrificial pattern layercontacts the insulating layer of the light-emitting diode element andthe connection patterns.
 5. The light-emitting apparatus according toclaim 3, wherein a distance between a surface of one of the pads incontact with one of the connection patterns and the substrate is greaterthan a distance between a surface of another of the pads in contact withanother one of the connection patterns and the substrate.
 6. Thelight-emitting apparatus according to claim 3, wherein a thickness ofone of the pads is greater than a thickness of another one of the pads.7. The light-emitting apparatus according to claim 3, wherein a distancebetween a surface of one of the pads in contact with one of theconnection patterns and the substrate is substantially equal to adistance between a surface of another of the pads and the substrate iscontact with another of the connection patterns.
 8. The light-emittingapparatus according to claim 3, further comprising: an auxiliaryconductive pattern, disposed on one of the pads and electricallyconnected to the one of the pads, wherein the auxiliary conductivepattern is disposed between the one of the pads and the correspondingconnection pattern disposed on the one of the pads.
 9. Thelight-emitting apparatus according to claim 8, further comprising: afirst dielectric layer, disposed on the pads and having a first contactvia, wherein the auxiliary conductive pattern is disposed on the firstdielectric layer and electrically connected to the one of the padsthrough the first contact via.
 10. The light-emitting apparatusaccording to claim 9, wherein the first dielectric layer further has asecond contact via, the second contact via overlaps another one of thepads, and one of the connection patterns is electrically connected tothe another one of the pads through the second contact via.
 11. Thelight-emitting apparatus according to claim 1, further comprising: asecond dielectric layer, disposed on the pads and having a plurality ofcontact vias respectively overlapping the pads; a plurality ofinterconnection patterns, disposed on the second dielectric layer, andelectrically connected to the pads respectively through the contact viasof the second dielectric layer; wherein the sacrificial pattern layer isdisposed on the second dielectric layer, and the connection patterns ofthe light-emitting diode element are electrically connected to theinterconnection patterns respectively.
 12. The light-emitting apparatusaccording to claim 1, wherein the sacrificial pattern layer serves as abonding layer, and a material of the sacrificial pattern layer comprisesa photoresist or a heat curing adhesive.
 13. The light-emittingapparatus according to claim 1, wherein each of the connection patternshas a curve surface.
 14. The light-emitting apparatus according to claim1, wherein the sacrificial pattern layer is overlapped with theconnection patterns in the normal direction of the substrate.
 15. Thelight-emitting apparatus according to claim 1, wherein a top surface andthe outermost sidewall of the sacrificial pattern layer are completelycovered by the first type semiconductor layer and the connectionpatterns so that no gap exists between the sacrificial pattern layer andthe light-emitting diode element.
 16. The light-emitting apparatusaccording to claim 1, wherein the connection patterns separate thesacrificial pattern layer from contacting the electrodes.